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Edition 1
Procedures For Loading and Off-loading Liquid Chlorine Containers Edition 1
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For cultural, legal and historical reasons it is not possible to have a common
detailed document applicable throughout the world. This document focuses on the
most important items necessary to safely handle chlorine during loading and off-
loading operations.
It is highly recommended that all national and local legislation concerning chlorine
transportation and safety are carefully checked for compliance.
Procedures For Loading and Off-loading Liquid Chlorine Containers Edition 1
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TABLE OF CONTENTS
1 GENERAL INFORMATION 6
1.1 Location 6
1.1.1 Location of the Loading /Off-loading Operation Point 6
1.2 Access Platform 7
1.2.1 Pipework, Valves, Accessories 7
1.2.2 Movement of the Shipping Container 7
1.2.3 Movement of Small Containers 8
1.3 General Protection 8
1.4 Personnel in Charge of Loading and Off-loading Operation 9
1.5 Personal Protective Equipment 9
1.6 Nitrogen Trichloride Risk 9
1.7 Choice of Connections 9
1.7.1 Articulated Arms 10
1.7.2 Flexible Hoses 10
1.7.3 Flexible Steel Pipes 10
1.7.4 Hoses for Instrument Air 10
1.8 Relief Valves 10
1.9 Absorption System 11
1.10 Protection against Liquid Expansion 11
1.11 Protection and Alarms 11
1.12 Accident Reporting 12
2 LOADING 12
3 OFF-LOADING 17
5 APPENDICES 24
6 CHECKLISTS 32
7 REFERENCE DOCUMENTS 39
TABLE OF FIGURES
APPENDIX 1: FLOW FOR FILLING A CONTAINER WITH CHLORINE PUMP 25
APPENDIX 2: FLOW FOR FILLING A CONTAINER BY CHLORINE GAS
PRESSURE 26
APPENDIX 3: OFF-LOADING TO USER IN THE GASEOUS PHASE 27
APPENDIX 4: OFF-LOADING TO USER IN THE LIQUID PHASE WITH DRY
GAS PRESSURE 28
APPENDIX 5: OFF-LOADING TO STOCK TANK IN THE LIQUID PHASE WITH
DRY GAS PRESSURE 29
APPENDIX 6: OFF-LOADING TO STOCK TANK IN THE LIQUID PHASE WITH
COMPRESSOR 30
APPENDIX 7: FLOW FOR FILLING A LIQUID CHLORINE TON CYLINDER 31
Procedures For Loading and Off-loading Liquid Chlorine Containers Edition 1
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1 GENERAL INFORMATION
This information is provided to assist companies involved with the loading and off-
loading of chlorine. It is not intended as a substitute for the relevant national or
international regulations. The user should review the National and Local
regulations as these can be very different depending on the country. Following
are some examples of different requirements:
In North America and Russia, railcars must have relief devices
whereas these are not used in Europe.
Russian legislation bans off-loading of chlorine in the gas phase for
containers over 1 cubic meter. It is allowed with constraints on
smaller cylinders. In other countries off-loading by vapour is common
practice for chlorine cylinders
Plastic hoses with reinforced metal covering are typically used in
North America but are not recommended in Europe
1.1 Location
1.1.1 Location of the Loading /Off-loading Operation Point
The Loading / Off-loading location should be:
Above ground level
On a level area to minimize the chance of accidental car movement
with sufficient clearance from other equipment
Adequately separated from traffic
As close as possible to the chlorine user or storage (minimizes length
of pipelines)
Accessible from at least two directions
Separated from other facilities and especially from potential sources of
heat
Preferably covered by a roof to protect the workers and the equipment
from snow, rain and sun
Complete with concrete flooring
Equipped with leveled rails to allow for the slow rolling of chlorine
tonner cylinders
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The piping systems (liquid chlorine, gaseous chlorine, vent system, dry inert gas),
should be clearly marked (for example, by the use of a color code) in order to
provide for immediate identification by the operating personnel.
The open-close position of the major valves should also be identified. This
feature is particularly important for pneumatic valves where the valve position may
not be easy to recognize.
Movement of the vehicle by gravity can be avoided if the location has no slope
and the rails are level. Unauthorized movement of the vehicle and the container
can be prevented by the use of wheel chocks. Access by other vehicles to the
loading/off-loading facility must be prevented. This can be accomplished by the
use of rigid barriers which are preferably locked into position. In the case of a rail
loading/off-loading installation movable buffers, or locked-off rail points can be
used. Similar measures should be taken for road vehicles.
If the container is fitted with automated pneumatic valves the opening of these
should be interlocked with the protective systems that prevent movement of the
container or access to the station by other vehicles.
For loading/off-loading of road tankers, it is preferred that the truck only moves in
the forward direction. This eliminates the additional risk associated with the
vehicle backing into or out of the location. Before the transport vehicle is
disconnected from the container it must be verified that the drop legs are strong
enough, that they have been locked into position and that the ground is solid
enough to prevent roll over.
The loading/ off-loading point should have adequate lighting. There must be a
visual indication that the container is in the loading/off-loading step. This includes
anytime it is not safe to move the container.
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Sufficient clearance must be provided between the container and the loading/off-
loading facility. If the container is moved with the dome open it can not come into
contact with any part of the facility. The valve access platform will be designed to
allow safe and easy access and there will be no possibility of the access platform
striking the container. If the access platform has adjustable elevations then the
stairway must accommodate all positions to allow safe access.
To facilitate the local intervention, the installation of fixed water curtains or mobile
water sprays should be considered. Provisions should then be taken to avoid
possible discharge of water onto the liquid chlorine or onto the area of leakage.
Breakaway coupling devices are used at some facilities to prevent releases if the
container is inadvertently moved during loading/off-loading operations; alternative
technical measures can also be taken to avoid any possible movement of the
container.
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This equipment is recommended only for installations requiring a high flow rate,
i.e. operations transferring directly into fixed storage. These devices are not
recommended for off-loading at low rates on a continuous basis directly to the
point of use
It must be noted that the use of flexible steel pipes on liquid chlorine is forbidden
in some countries.
Copper can be used in this duty with smaller diameter piping (<25 mm). It should
also be stress-relieved on a regular basis to maintain the flexibility of the metal
and to avoid cracks.
In North America, the motive force may be required to both open and close the
valves. In this case a hose reel is provided such that if the railcar is moved the
hoses will stay connected long enough for the valves to be fully closed. Motion
detectors at the railcar detect movement and automatically close the valves.
In Europe and some other areas, these valves require that air be applied to open
them. Upon loss of air, the valves will automatically close. In this case the
length of air hoses should be shorter than the chlorine hose. If the railcar is
moved the shorter air hose will fail first resulting in the fail safe closing of the
chlorine valves.
Fixed site chlorine storage tanks typically are required to have relief valves. In
many cases, a rupture disc is installed upstream of the relief valve. In such cases
the space between the rupture disc and the relief valve must be monitored to
insure that no leakage has occurred and the disc will function as intended (i.e.,
rupture in the event of over-pressure).
It is preferable that these valves are grouped together in the same location. In so
far as protection against expansion of liquid chlorine trapped between two valves
is involved, see Section 1.9.
2 LOADING
A written checklist should be used during all operations, including, as appropriate,
the approval of a supervisor before starting loading the equipment.
The compressed gas source being used on the storage tank should not be
connected to any other installation unless a detailed review has been conducted.
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Protection must be installed to prevent chlorine from back flowing into the air
system. Even where not required by the regulatory authorities, many facilities
have found it beneficial to separate the chlorine pad air system from other
systems to avoid their contamination.
Instrument air should not be used for pressurizing the storage tank. This
eliminates the risk of chlorine being backed into the control and safety systems.
Care must be taken to ensure excess inert gas does not result in an over-
pressure situation.
Before loading all containers should then be inspected to ensure that they are in a
proper state to receive chlorine. These checks in particular include the following:
The container is a suitable transport vehicle for liquid chlorine
(labeling).
The date when it was last inspected and the date of the next
inspection.
The maximum pressure and the minimum temperature for which the
container and accessories have been constructed.
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The weight of the container should be compared with its tare weight. The gas
tightness of the valves should be checked after removal of the blank flanges (to
be confirmed by ammonia water). For this operation the operator should be
wearing respiratory protection.
Important: when areas are searched for possible chlorine leaks using an
ammonia solution, only the gas from the bottle should be directed to the
equipment. Never squirt liquid ammonia solution on the potential leak source! The
reaction between liquid ammonia and chlorine is quite violent and must be
avoided.
After attaching the gaseous phase connection and its motive fluid, one should
open the various valves which will give a reliable indication of the existing
pressure within the container.
Note: All joint rings or gaskets on the flexible connections should be replaced
with each connection and the flange faces should be cleaned. The connections
must be made correctly in accordance with the manufacturers recommendations.
This is to avoid any failures in this area. The operator should attach particular
importance to this operation.
Confirm that all the valves on the installation are in the right position and that in
particular the connection between the liquid or gaseous chlorine systems and the
vent gas absorption system has been closed.
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The valves on the fixed installation should be opened slowly in order to confirm
that there are no leaks on any of the connections. During the loading operation
the gas valve of the container can remain open in order to avoid an excessive
increase in pressure. The vent gas should then be directed towards:
Either the absorption system initially where there is an excessive
quantity of inert gas present, and then towards the chlorine production
system
Or directly to the chlorine producing unit
It is essential that the total load is effectively checked before any transport vehicle
leaves the loading installation. Overfilling a container can result in over-pressuring
it due to thermal expansion of the chlorine. Each country may have different
requirements on the maximum amount of chlorine allowed in each container.
Compliance with the local laws is required. The maximum filling ratio must not be
exceeded (1.25 tonnes per m 3 of water capacity, and in every instance a
minimum of 5% free board at the maximum operating temperature).The methods
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for controlling the total load are limited to the following in order of preference
(preferably by continuous measurement).
Measurement of the total weight of the filled container
The maximum gross weight must be carefully checked. In order to calculate the
net weight, it is essential that the possible presence of residual chlorine in the
container before loading has been adequately taken into account, Cross check
the tare weight with the original tare weight for the vehicle being filled.
Filling from a weighed stock tank
Volumetric filling (difference in level, etc.)
In the two latter cases strict control must be maintained over the initial and final
gross weight. It is also necessary to ensure that the vehicle was empty before
commencing filling, e.g. by venting down. As soon as possible after loading, the
total weight must be checked on a weigh scale. This must be done prior to
allowing the vehicle to leave the facility.
During the complete loading operation the loading point should be under continual
supervision, either in person or by the use of cameras and detectors.
Some facilities quarantine the filled containers for 24 hrs to allow the loaded
material to achieve room temperature and higher container pressure. They then
recheck for leaks, container test dates and correct quantities (weights)
3 OFF-LOADING
A written checklist should be used during all operations, including, if appropriate
the approval of a supervisor before starting off-loading the equipment.
By this means an intermediate storage system for liquid chlorine, with all the
implications for inspection and maintenance, can be avoided.
It can only be used for small containers and for an installation using chlorine gas
at low pressure (the order of 2 bars absolute). A careful study is needed because
the pressure in the container resulting from the thermal equilibrium with ambient
conditions is limited to a fairly small value. This can lead to the backflow of
moisture or reactive materials into the container. It is also more difficult to control
the off-loading rate. See Appendix 3.
The extraction rate depends upon the conditions of thermal equilibrium with the
outside temperature and is usually limited to an off-loading rate of 150 kg/hour.
In any case, the supplier of the liquid chlorine needs to inform the chlorine user of
the risk of nitrogen trichloride concentration. If this method of off-loading in the
gaseous phase is employed the supplier must take appropriate measures to avoid
NCl3 accumulation in the tank.
The pressurization gas must be dry and have back flow prevention installed.
Chorine compressors may also be used to compress vapour from the fixed
storage for use as pad gases to remove liquid from the transport tank.
Temperature in the transport tank should be maintained at a level such that the
chlorine gas from the compressor will not liquefy and possibly overfilling the
transport tank rather than increasing the pressure to pad the liquid out.
This system can only be used where the container is off-loaded towards a fixed
storage installation. See Appendix 6.
The risk of contact between chlorine and the lubrication oil of the
machine must be eliminated, unless special greases are used which
are non-reactive to chlorine e.g. chloro-fluorinated grease.
The risk of recycling chlorine liquid into the compressor inlet must be
eliminated. Liquid entrainment in the chlorine gas to the compressor
inlet must also be prevented.
The temperature of chlorine in the compressor should be limited to
120C by various safety measures which provide for shut-down of the
compressor if this limit is exceeded. This is to prevent a chlorineiron
fire.
If the compressor is cooled, care must be taken to ensure that no
water can enter the chlorine stream.
This method, although not recommended in North America, can be used provided
the following safety provisions are applied:
Maximum temperature of the vessel less than 50C (40C in Japan)
(usually based on the design pressure of the vessel).
Maximum temperature of the heating source less than 120C (to avoid
reaction between iron and chlorine).
Direct steam, infrared heaters and electric tracing shall not be used
because of the risk of overheating.
When off-loading into a storage tank, select the storage tanks to be used and
ensure that there is sufficient volume available to contain the chlorine.
Confirm that the nature and quantity of product contained in the container is
correct as indicated (labeling and consignment notes).
Carry out a visual check of the adequate state of valves and flanges which are to
be used in the connections. All defects should be notified immediately to the
chlorine supplier.
Check on the wheel chocks and other protective devices to ensure that the
container cannot be moved during its loading operation, as indicated in Section
1.1.
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3.3.1.2 Connections
Note: All joint rings or gaskets on the flexible connections should be replaced with
each connection and the flange faces should be cleaned. The connections must
be made correctly in accordance with the manufacturers recommendations. This
is to avoid any failures in this area. The operator should attach particular
importance to this operation.
3.3.2 Off-loading
The station should be equipped with a device to quickly shutoff the valves at the
tank in the event of an emergency. Consideration should be given to having area
chlorine sensors that will detect chlorine leaks and automatically close the valves
at the tank.
Before starting the off-loading, ensure that all valves on the installation are in the
correct position, and, in particular, verify that the connection from the liquid and
gaseous chlorine piping to the absorption system has been closed. If the off-
loading is carried out by pad gas pressure, adhere to the recommendations of
Section 3.2.1 and ensure that the gas dryness and the differential pressure
between the container being emptied and the storage system are maintained.
Whatever the destination of the chlorine being off-loaded (direct use or storage
system), the container being emptied should be under continuous supervision,
either visually or by television monitor. Automatic means to detect chlorine
releases should also be installed.. The user must also be able to check the
quantity of chlorine remaining in the container, confirm no contamination has
occurred, and that pressures are not increasing due to the presence of inert gas.
operation should be carried out in order to avoid any possibility of the maximum
operating pressure of the container being exceeded during its return journey.
This purging operation should be carried out until the disappearance of any
frosting. After venting down, the flexible connections should be maintained under
a dry air or nitrogen purge.
3.3.5 Disconnection
For these operations it is recommended that the operating personnel should wear
breathing protection equipment. These operations should be carried out in the
following order:
Disconnect the motive force for the container automated valves.
Manually close the pneumatic valves on the chlorine container
Disconnect the chlorine connections
Check the gas tightness of the container valves
Reinstall the blind flanges with a new ring joint or gasket on the valves
of the transport container
Isolate of the flexible connections and of the fixed installation flanges
with a blind flange in order to avoid their contamination due to
atmospheric humidity
All precautions should be taken to avoid the movement of the container during the
course of loading.
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Gland nuts should be checked for any cracks, roundness of the corners, and for
uniform thickness of the Teflon packing. Gland nuts should be rejected if they
have defects that might make them less than fully reliable.
Other techniques are also used by JSIA (temperature and/or pressure alarm).
The driver of the transport truck should be trained and should have all of the
necessary instructions and protective equipment to respond to possible incidents
with a chlorine leak.
5 APPENDICES
Appendix 1: Flow for filling a container with chlorine pump
Appendix 2: Flow for filling a container with chlorine gas pressure
Appendix 3: Off loading to user in the gaseous phase
Appendix 4: Off loading to user in the liquid phase with dry gas pressure
Appendix 5: Off loading to stock tank in the liquid phase with dry gas pressure
Appendix 6: Off loading to stock tank in the liquid phase with compressor
Appendix 7: Flow for filling a liquid chlorine ton cylinder
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6 CHECKLISTS
Sample checklists have been prepared to assist the user of this document in
verifying compliance with key aspects of the topic area. These sample
checklists were prepared by a regional association member (AMAI) of WCC.
Not all of the items listed may be applicable to the users region. The user is
encouraged to review the checklists provided and modify them as deemed
appropriate for use at the users site. The check lists should not be considered
all-inclusive of the recommendations in this publication. The checklists have
been designed to emphasize major topics for someone who has already read
and understood the publication. Taking recommendations from such checklists
without understanding related topics can lead to inappropriate conclusions.
Yes No N/A
Is the storage location SHADED and DRY?
Is there ADEQUATE ventilation?
Is there no source of heat NEARBY?
Are there ANY OTHER chemicals stored in the
area?
Are there any corrosive fumes from NEARBY
area?
Is the area NEAT and CLEAN?
Is the gangway FREE?
Is the container SECURED with wooden wedges
on BOTH SIDES?
Are filled tonners arranged in a SINGLE ROW?
Are there SEPARATE ROWS for empty tonners?
Are the valves in a VERTICAL plane?
Are the tags CORRECT?
Is there SPECIFIED DISTANCE from the
connected tonners in the process?
Is there no hot job WITHOUT a work permit?
Are unauthorized persons PROHIBITED from
entering?
Is an Emergency Kit ready at an IDENTIFIED
PLACE?
Is self-contained breathing apparatus located at
an IDENTIFIED PLACE?
Do tonners not lie for MORE THAN ONE MONTH
unused?
Is there a PERIODIC CHECK for leakage with an
ammonia torch?
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Yes No N/A
Has leakage been CHECKED for with an
ammonia torch?
Is the spindle of the valve in the CORRECT
SHAPE?
Are the valve caps FITTED?
Is the valve protection hood (bonnet) FITTED?
Has the PHYSICAL CONDITION of the tonner
been checked?
Has the hydraulic TEST DATE been checked?
Are BOTH SIDE COVERS of vehicles operable?
Is there a vehicle without a top hood?
Is the breadth of the vehicle slightly MORE THAN
the length of the tonner?
Is the vehicle NOT LOADED with paints, oils,
grease, turpentine and food?
Is an Emergency Kit KEPT in the vehicle?
Is a CO2 type fire extinguisher KEPT in the
vehicle?
Are breathing apparatus, gas mask KEPT in the
vehicle?
Is there a CORRECT emergency information
panel?
Are required and optional safety materials kept
WITH THE DRIVER?
Is the vehicle COVERED with a tarpaulin?
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Yes No N/A
Has it been verified that the vehicle is STOPPED
and brakes APPLIED?
Are tonners in a SINGLE ROW?
Are tonners SECURED WITH wooden wedges,
rope / sling wire?
Are there NOT MORE THAN SIX tonners in a
vehicle (standard size)?
Are tonners not PROJECTED outside the
vehicle?
Is the tonner valve in a VERTICAL plane?
Yes No N/A
Have the brakes been CHECKED?
Does the driver drive at the speed LIMIT?
Is the driver not UNDER THE INFLUENCE of
alcohol?
Has the vehicle been checked for leakage with
an ammonia torch?
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Yes No N/A
Have vehicle brakes been APPLIED and is the
engine STOPPED?
Is the vehicle under the SUPERVISION of a
trained and experienced person?
Is a crane/hoist/chain pulley block being USED?
Are tonners NOT BEING DROPPED DIRECTLY
to the ground?
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Yes No N/A
Container ON weighting platform?
Are tonners SECURED WITH wooden wedges
on BOTH SIDES?
Are valves in VERTICAL planes?
Are STANDARD tools and accessories being
used?
Are pressure gauges in WORKING CONDITION?
Are the inverted U loop / non-return valve IN
SERVICE?
Is the pressure regulating valve IN SERVICE?
Is a neutralization system AVAILABLE?
Is the Emergency Kit IN ORDER?
Is self-contained breathing apparatus
AVAILABLE?
Has an ammonia torch been used to CHECK for
leakage?
Is connection made with YOKE CLAMPS and
COPPER TUBING?
Is the valve key kept FIXED to all the valves in
service?
Are tonners NOT BEING USED as process
vessels?
Are tonners used in ORDER OF RECEIPT?
No tonner HEATING for withdrawing more
chlorine?
Is there slight POSITIVE chlorine pressure in the
empty tonner?
Has it been verified that no lubricant or oil is
NEAR the chlorine tonners?
Are TEFLON gaskets being used?
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Yes No N/A
Are breathing apparatus / canister gas mask and
safety appliances being USED while
DISCONNECTING?
Was this sequence for disconnecting the tonner
followed:
CLOSE tonner valve;
CLOSE process valve;
NEUTRALIZE trapped chlorine;
DISCONNECT fittings.
Valve cap FITTING secure?
Has the valve protective device (bonnet) been
FITTED?
Has the tonner TAG been emptied?
STACKING in empty tonner row?
Are the valves in a VERTICAL plane?
Has this final check been made before dispatch:
Verify PHYSICAL CONDITIONS of tonners and
valves;
Verify FITNESS of valve caps and protective
device (bonnet)
Has any ABNORMAL observation been
conveyed to the supplier?
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7 REFERENCE DOCUMENTS
7.5 RusChlor
Safe Rules for the Production, Transportation, and Use of Chlorine (available
only in Russian)